Contents:
3-cyl. injection engine (1.0 l engine, 4V, EA 211 EVO) DFN A, DFN B, DSG B, DSG D, DSG C – 382
Technical data
Safety information:
1.1 Safety regulations for working on fuel supply
1.2 Safety measures when working on vehicles with a start/stop system
1.3 Safety precautions when using testers and measuring instruments during a road test
1.4 Safety precautions when working on the cooling system
1.5 Safety precautions when working on ignition system
Identification:
2.1 Engine number/engine data
Repair instructions:
3.1 Rules for cleanliness
3.2 General information
3.3 General repair instructions
3.4 Foreign objects in engine
3.5 Contact corrosion
3.6 Routing and attachment of lines
3.7 Fitting radiator and condensers
3.8 Checking vacuum system
Removing and installing engine:
1 Removing and installing engine
1.1 Removing motor
1.2 Separating engine and gearbox
1.3 Securing engine on engine and gearbox support
1.4 Installing engine
Assembly mountings:
2.1 Assembly overview – assembly mountings
2.2 Removing and installing engine mounting
2.3 Removing and installing gearbox mountings
2.4 Removing and installing pendulum support
2.5 Supporting engine in installation position
2.6 Adjusting assembly mountings
2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
Crankshaft group:
1 Cylinder block (pulley end)
1.1 Assembly overview – poly V-belt drive
1.2 Removing and installing poly-V belt
1.3 Removing and installing tensioner for poly V-belt
1.4 Removing and installing vibration damper
1.5 Removing and installing engine support
1.6 Renewing crankshaft oil seal – belt pulley end
1.7 Removing and installing sealing flange on pulley end
2 Cylinder block, gearbox end
2.1 Assembly overview – cylinder block, gearbox end
2.2 Removing and installing flywheel
2.3 Removing and installing sealing flange on gearbox side
3 Crankshaft
3.1 Crankshaft dimensions
4 Pistons and conrods
4.1 Assembly overview – pistons and conrods
4.2 Checking pistons and
4.3 cylinder bores
4.4 Removing and installing oil spray jets
4.5 Setting piston to TDC position
Cylinder head, valve gear:
1 Cylinder head
1.1 Assembly overview – cylinder head
1.2 Removing and installing cylinder head
1.3 Removing and installing camshaft housing
1.4 Checking compression
2 Toothed belt drive
2.1 Assembly overview – toothed belt cover
2.2 Assembly overview – toothed belt
2.3 Removing and installing toothed belt guard
2.4 Removing and installing toothed belt
2.5 Preassembling and installing valve timing tool
2.6 Checking valve timing
2.7 Adjusting valve timing
2.8 Removing toothed belt from camshaft
3 Valve gear
3.1 Assembly overview – valve gear
3.2 Removing and installing camshaft oil seal
3.3 Removing and installing camshaft adjuster
3.4 Removing and installing camshaft control valve 1 N727
3.5 Removing and installing exhaust camshaft control valve 1 N318
3.6 Removing and installing valve stem seals
3.7 Removing and installing holder for oil seal
4 Inlet and exhaust valves
4.1 Checking valve guides
Lubrication:
1 Sump, oil pump
1.1 Assembly overview – sump/oil pump
1.2 Engine oil
1.3 Removing and installing oil sump
1.4 Removing and installing oil pump
1.5 Removing and installing oil level and oil temperature sender G266
2 Crankcase ventilation
2.1 Assembly overview – crankcase breather system
2.2 Removing and installing oil separator
3 Oil filter, oil pressure switch
3.1 Assembly overview – oil pressure switches/oil pressure control
3.2 Removing and installing oil pressure sender G10
3.3 Checking oil pressure and oil pressure switch
3.4 Removing and installing oil filter housing
3.5 Removing and installing oil pressure regulating valve N428
Cooling:
1 Cooling system/coolant
1.1 Connection diagram – coolant hoses
1.2 Checking cooling system for leaks
1.3 Draining and adding coolant
2 Coolant pump, regulation of cooling system
2.1 Assembly overview – coolant pump, thermostat
2.2 Assembly overview – coolant temperature sender
2.3 Removing and installing coolant pump
2.4 Removing and installing toothed belt pulley for coolant pump
2.5 Removing and installing coolant temperature sender G62
2.6 Removing and installing engine outlet coolant temperature sender G82
2.7 Removing and installing engine temperature regulation module GX33
2.8 Checking coolant pump
3 Coolant pipes
3.1 Assembly overview – coolant pipes
3.2 Removing and installing coolant pipes
4 Radiator, radiator fan
4.1 Assembly overview – radiator/radiator fan
4.2 Assembly overview – radiator cowl and radiator fan
4.3 Removing and installing radiator
4.4 Removing and installing radiator cowl with radiator fan
4.5 Removing and installing radiator fan VX57
Mixture preparation – injection:
1 Injection system
1.1 Overview of fitting locations – injection system
2 Injectors
2.1 Assembly overview – fuel rail with injectors
2.2 Removing and installing injectors
2.3 Checking injectors
3 Air filter
3.1 Assembly overview – air filter housing
3.2 Removing and installing air filter housing
3.3 Removing and installing resonator for intake air
3.4 Removing air duct on lock carrier
4 Intake manifold
4.1 Assembly overview – intake manifold
4.2 Removing and installing intake manifold
4.3 Removing and installing throttle valve module GX3
4.4 Cleaning throttle valve module GX3
5 Senders and sensors
5.1 Removing and installing intake manifold sender GX9
5.2 Removing and installing fuel pressure sender for low-pressure G410
6 Engine control unit
6.1 Assembly overview – engine control unit
6.2 Removing and installing engine control unit J623
6.3 Removing and installing engine (motor) control unit J623 with protective housing
7 Lambda probe
7.1 Assembly overview – Lambda probe
7.2 Removing and installing Lambda probe
Exhaust system:
1 Exhaust pipes and silencers
1.1 Assembly overview – silencers
1.2 Separating exhaust pipes from silencers
1.3 Removing and installing silencer
1.4 Aligning exhaust system free of stress
1.5 Checking exhaust system for leaks
1.6 Installation position of clamp
2 Emission control
2.1 Assembly overview – emission control
Ignition system:
1 Ignition system
1.1 Assembly overview – ignition system
1.2 Removing and installing ignition coils with output stage
1.3 Removing and installing knock sensor 1 G61
1.4 Removing and installing engine speed sender G28
1.5 Removing and installing inlet camshaft position sender G1002
1.6 Removing and installing exhaust camshaft position sender G1003
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